General Information

General Information

Vehicle Protection. Always cover the fenders, seats and floor before starting work.Preparation of Tools and Measuring Equipment: Make sure all necessary tools and measuring equipment are available before starting work. Special Service Tools: Use special service tools when required.

Removal of Parts: First find the cause of the problem, then determine whether removal or disassembly is required before starting work.

Disassembly: If the disassembly procedure is complex and requires removing many parts, all parts must be disassembled in such a way that their function or appearance is not affected.

1. 1
   Inspection of Parts: Inspect each removed part carefully for malfunction, deformation, damage, and other problems.

   

2. 2
   Arrangement of Parts: Arrange all disassembled parts neatly for efficient reassembly. Be sure to separate and properly identify parts that are to be replaced from those that will be reused.

   

3. 3
   Cleaning of Parts for Reuse. All parts that will be reused must be thoroughly cleaned using an appropriate method.

   

   

4. 4
   Oil Seals
5. 5
   Gaskets
6. 6
   O-rings
7. 7
   Lock Washers
8. 8
   Cotter Pins
9. 9
   Plastic Nuts

   

   Depending on their location.
10. 10
    Apply sealant to gaskets.
11. 11
    Apply oil to the moving parts.
12. 12
    Apply the specified oil or grease to the specified locations (oil seals, etc.) before assembly.

    

13. 13
    Be sure to disconnect the battery cable from the negative (-) battery terminal.
14. 14
    Never pull on the wires when disconnecting connectors.
15. 15
    Locking connectors will click when securely connected.
16. 16
    Handle sensors and relays carefully. Be careful not to drop them onto other parts.

    

    

17. 17
    Basically, all measurements in this manual are made with a tracking measuring tape.
18. 18
    When using a measuring tape, make sure it is not stretched, twisted, or bent.
19. 19
    Both projected and actual dimensions are used in this manual for measuring dimensions.
20. 20
    These are dimensions measured by projecting the measuring points from the vehicle surface, and are reference dimensions used for body modification.
21. 21
    If the length of the tracer probes can be adjusted, measure it by extending one of the two probes until there is no difference in height between the two surfaces.

    

22. 22
    These dimensions indicate the actual linear distance between points and are used as reference dimensions when measuring.
23. 23
    First adjust both probes to the same length (A=A') before measuring.

    

    

24. 24
    Check the terminal for tightness.
25. 25
    Check terminals and wires for corrosion from battery electrolyte, etc.
26. 26
    Check terminals and wires for open circuits.
27. 27
    Check wire insulation and coating for damage, cracks, and wear.
28. 28
    Check the conductive parts of the terminals for contact with other metal parts (vehicle body and other components).
29. 29
    Check the grounded parts to make sure there is continuity between their mounting bolt(s) and the vehicle body.
30. 30
    Check for correct connections.
31. 31
    Make sure the wiring is secured so that it does not contact sharp body edges, corners, etc., or hot parts (exhaust manifold, etc.).
32. 32
    Make sure the wiring is securely fastened to provide sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
33. 33
    Make sure the wiring has enough slack to vibrate between stationary and moving parts, such as the body and the engine.

    

    

34. 34
    Before servicing the electrical system, be sure to turn the ignition switch OFF and disconnect the battery ground cable.

    

35. 35
    Secure wiring harnesses with clips so that they do not sag. However, for any harness that passes near the engine or other vibrating parts of the vehicle, allow some slack within a range that prevents engine vibration from bringing the harness into contact with any surrounding parts, then secure the harness with a clip.

    

36. 36
    If any section of the wiring harness contacts the edge of a part or a corner, wrap that section of the harness with tape or similar material to protect it from damage.

    

37. 37
    When installing any parts, take care not to pinch or damage the wiring harness.

    

38. 38
    Never drop relays, sensors, or electrical parts, and do not subject them to strong shocks.

    

39. 39
    Electronic parts used in computers, relays, etc. are easily damaged by heat. If there is a need for service operations that may cause the temperature to rise above 80 °C, remove the electronic parts beforehand.

    

40. 40
    Loose connectors cause problems. Make sure connectors are always securely connected.

    

41. 41
    When disconnecting a connector, hold only the connector, not the wires.

    

42. 42
    Disconnect the connector with locks by pressing in the direction of the arrows shown in the illustration.

    

43. 43
    Connect connectors with locks by inserting them until they click.

    

44. 44
    When using a circuit tester to check continuity or voltage at a connector terminal, insert the test probe from the harness side. If the connector is a waterproof connector, insert the test probe through the hole in the rubber cap until it contacts the terminal, taking care not to damage the wire insulation.

    

45. 45
    To prevent overloading the wiring, take the current load of additional equipment into account and select the appropriate wire size.

    Nominal size	SAE Gauge No.	Allowable Current
    		In Engine Compartment	Other Areas
    0.3 mm²	AWG 22	-	5A
    0.5 mm²	AWG 20	7A	13A
    0.85 mm²	AWG 18	9A	17A
    1.25 mm²	AWG 16	12A	22A
    2.0 mm²	AWG 14	16A	30A
    3.0 mm²	AWG 12	21A	40A
    5.0 mm²	AWG 10	31A	54A

Parts: When replacing parts, use genuine KIA MOTORS parts. Standard values such as torque and specified adjustments must be strictly observed when assembling all parts. After removal, the following parts must always be replaced with new ones. Adjustment: Use gauges and testers to correctly adjust parts to standard values. Electrical System: Rubber parts and tubes: Always avoid contact of gasoline with rubber parts or tubes. Body Dimensional Measurement: Overall dimensions, measurement of actual dimensions, measuring point. Measurements should be taken at the center of the hole. Inspection of Cables and Wires: Inspect Fuses. Test points are provided for checking blade-type fuses, allowing the fuse to be checked without removing it from the fuse block. The fuse is good if the test lamp lights when one lead is connected to a test point (one at a time) and the other is grounded. (Turn the ignition key to activate the fuse circuit.) Electrical System Service: Precautions for Catalytic Converter

1. 1
   Use only unleaded gasoline.
2. 2
   Do not run the engine when the vehicle is stationary for a long time. Avoid running the engine at high idle speed for more than 10 minutes or at idle for more than 20 minutes.
3. 3
   Do not perform engine compression testing for an extended period. Complete engine compression tests as quickly as possible. Remove the fuel pump relay before performing the compression test.
4. 4
   Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.